ML20002A562
| ML20002A562 | |
| Person / Time | |
|---|---|
| Site: | Washington Public Power Supply System, Satsop |
| Issue date: | 10/02/1980 |
| From: | Bishop T, Haist D, Haynes R, Kirsch D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | Spencer G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| Shared Package | |
| ML20002A545 | List: |
| References | |
| NUDOCS 8011200135 | |
| Download: ML20002A562 (12) | |
Text
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'b UNITED STATES
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- g NUCLEAR RL'GULATORY COMMISSION g-t; j
REGION V 1990 N. CAle?ORNIA BOULEVARD o
g SUITE 202.WALr6UT CREEK PLAZA g *,,,,,e WALNUT CREEK. CALIFORNIA 94696 O
October 2, 1980 MEMORANDUM FOR:
G. S. Spencer, Chief, Reactor Construction and Engineering Support Branch FROM:
Regional Evaluation Review Board - WNP 3 and 5
SUBJECT:
REGIONAL EVALUATION OF llNP 3 and 5 The Regional Evaluation Review Board for WNP 3 and 5 met on September 5, 1980 to perform the evaluation of project activities for the period of August 1979 through August 1980. The board reviewed the following areas:
a.
Previous enforcement actions and results.
b.
Responsiveness and effectiveness of corrective actions taken regarding adverse findings identified as a result of the licensee's quality assurance program and NRC inspections.
c.
Licensee actions in the area of IE Bulletins and Licensee -
Event (Part 21 and 50.55(e)) Reports.
It is the opinion of the Board, based on the results of the review, that the licenwe's performance warrants improvement in assuring that adequate preparation and preplanning has been accomplished by a contractor prior to the start of safety related work and that PSAR and Code requirements and industry standards committed to are included in the contractor's program.
Additionally. URC:RV inspections should be enhanced in the review of the licensee's methods which assure that contractors are adequately prepared before executing safety related activities. Justifications for this recommendation are inconsistencies identified between the prime mechanical contractor's quality assurance manual and implementing procedures and the ASME B&PV Code and administrative site procedures and recent findings in the area of structural steel erection.
so1noo DS~
4 G. S. Spencer' Licensee actions related-to IE Bulletins, Circulars, Information Notices, and Licensee-Event Reports were generally satisfactory. No specific change in licensee programs or NRC. inspections in these areas is recommended at this time.
Regional Review Board Members:
C-w ]
R. C. Haynes,(Chigf, Reactor Construction Projects Section
,' JY 'd L -
/
i n
j ~xt D. F. Kirsch,' Reactor Inspector i
/?l WV
[f. P. Haist, Reactor Inspector-i ~
h.k ~
,Y T. W.,Bishoy, Resident Inspector
Enclosure:
WNP 3/5 Evaluation Fonn for Appraisal Period 8/79-8/80
.)
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,MC C955 APPENDIX B REGION y
LICENSEE PERFORMANCE EVALUATION (CONSTRUCTION)
Facility: Washington Nuclear Project Nos. 3 and 5 Licensee: Washington Public Power Supply System Unit Identification:
Docket No.
CP No.'/Date of Issuance Unit No.
50-508 CPPR-154/ April 11,1978 3
50-509 CPPR-155/ April 11,1978 5
s Reactor Information:
Unit 3 Unit 5 NSSS-CE CE~
Mwt 3800 3800 Appraisal Period:
August 1979 - August 1980, Inclusive Appraisal Completion Date:
September 5, 1980 i
Review Boara Memoers:
D. F. Kirsch. Reactor Inspector (Principal Insp.1979-June 1980 D. P. Haist, Reactor Inspector (Current Principal Inspector)
T. W. Bishop, Resident Inspector (Assigned June, 1980)
R. C. Haynes, Chief, Project Section(Reactor Construction and Engineering Support Branch) 2955-B-1 4/15/80
MC 2955 (Apo. B)
A.
Numoer and Nature of Noncomoliance Items (See Attachments 1 and 2)
Noncompliance catecory:
. Unit 3 Unit g Violations-0 0
Infractions 8
3 Deficiencies-0 0
Areas of Noncomoliance:
-Unit 3 Unit 5 (List Areas as Required)
(Points)
-(Points)
(See Attached Summary)
(80)
(30)
~..
on en
]
Total Points B.
Nu oer and Mature of Daficiency Reoorts -(See Attachment 3) 1.
Unit 3 only: Rebar left out of fuel handling building wall: closed.
2.
Units 3&5: Fuel pool temperature gradients understated in design: closed.
3.
Units 3&S: Cracking in stainless clad overlay on shutdown heat exchanger.
flange: open.
C.
Bulletins and Circulars:
(See Attachment 4) Responses to IE Bulletins have generally been timely and adequate.
D.
Escalated Enforcement Actions Civil Penalties None Orders None immediate Action Letters 1.
Omission of rebar in fuel handling building wall:dtd November 7,1979:
50.55(e) report closed.
2955-B-2 4/15/80
~. ~
V
~MC' 2955L ( ADp, 8) a D.
Manacement: Conferences Held Durino Past Twelve Months'
- flone i
~
E.
Justification of-Evaluations of Functional Areas"Catecorized as Reouiring i
an increase in insoection Frecuency/Scoce (See evaluation sheet) 1
-(See Attachmenc 5).
I i
i 3
i i
)
w l
2955-B-3 4/15/30
~-
Attachme..t 1 ENFORCEMENT HISTORY
- IllSPECTOR
% COMPLETE-IrlSP llRS PER PLANT / PROJECT YEAR 110URS IllFRACTIONS DEFICIEf!CIES DEVIAT' IONS AT YR START EfiF. ACTI0tl
.tElP. 3/5
- 1980 430.5 4
0 0
19.5/7.9%
' 108
- 1979 531 10 0
0 9.1%/0,5%
-53 1978 450' 3
1 1
0%
105
- 1980 DATA'IS TilROUGil AUGUST 1980 7
i 4
4 s
s
Page 2 of 2 WNP-3/5 ENFORCEMENT HISTORY 60-2500 -
50-
- 100 2000 -90 I
w 40-t 80 3
M5 l'
d l-f 1500 -. 70 O
1 M
INSPECTION
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5
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b 30 -
HOURS Tf l-60 5
<n Af w
s 5
5 i
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$ 1000 -50 $
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20 -
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40
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l 200 '.30
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/
ITEMS OF NONCOMPLIANCE
/
10 -
/
20 f
/
( CONSTRUCTION
/
PROGRESS-
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I::st-CCT:c:a :w:lin:
0 _-10 rua ::c:: c::ptI;,::ct
/.105NC a3NC -108 NC 0
"0
'77
'78
'79
'80
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'82 o
1 ENFORCEMENT ACTIONS DURING PERIOD OF IHTEREST
~
REPORT
RESPONSE
RESPONSE REPORT REPLY e, TEM OIL NuttBER TYPE DATE LTR. NO.
LTR. DATE CLOSED AbE0llATE DESCRIPTION UNP-3 508/79-07-01 I
9-28-79 G03-79-1892 10-31-79 79-10 yes storage and identification of rebar 508/79-07-02 I
9-28-79 G03-79-1892 10-31-79 80-01 yes Improper weld preheat i
508/79-10-05 I
12-14-79 G03-80-91 01-18-80 80-02 yes Improper weld filler metal control 508/79-10-06 I
12-14-79 G03-80-91 01-18-80
- no Failure to requalify welding p' ocedura r
503/80-04-02 I
06-09-80 G03-80-1635 07-11-80 yes Improper velds on vendor supplied pipit.:
508/80-04-03 I
06-09-80 G03-80-1C35 07-11-80 yes 503/80-06-02 I
Failure.to identify itens passing.
required inspections 508/80-06-03 I
Failure to accomplish welding as required Uhd ~5 509/79-08-01 I
12-14-79 G03-80-91 01-18-80 80-02 yes Improper neld surface preparation 0
509/79-08-03 I
12-14-79 G03-80-91 01-18-80
- no Failure to requalify uelding procedure 1
509/80-05-02 I
Failure to identify items passing the required inspections Regulatory position recently obtained by RV required additional action by licensee.
I = Infraction
Attachm:nt 3 50.55(e)
HNP~3/5
~
~~" " CONSTRUCTION DEFICIENCIES
~
ITEM DESCRIPTION ISSUE /
RESPONSE
RESPONSE RESP. LTR.
REPORT NOTIFIED REQ. DATE RECEIVED NO./DATE CLOSED nATE
.1...
Rebar left out of fuel handlin9 2/06 G03 79.-2253 cartia /79 b1da wall (Unit 3 on1v) 11/ 02/7.,,
12/02/79 l
12-03.9 02/05/80 G03-80-199 final 01-31-80 80-02 Fuel pool wall temp gradients 03/07/80 G03-80 412 2
understated in desien (Units 3/5) nt/?q/9n n?/?A/Rn final 03-03-80 80-02 Cracking in stainless steel clad 06/27/80 G03-80-1516 3
overlav en shutdown heat exchanger 05/22/80 06/23/80 preliminary 06-25-80
.fiange..(Units 3/51 l
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Attachment G
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'f E Eullatins
'IrlP 3/5 XTEM CESCRIPTIO*l ISSUE /
RESP 0:!SE
RESPONSE
RESP. LTR.
REPORT
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79-03' 03/12/79 05/12/79 07/16/79 G03-79-1283 80-02' Incorrect WTS for Velan Swing Check 05/25/79 7'9-04 pim 03/30/79 05/30/79 05/29/79 No number
_80-02 Sei 06/12//9 o,smic. Stress Analysis of Safety 04/14/79 05/29/79 06/15/79 G03-79-1083 80-02' 79-07 om,4 pininn n
a 08/02//9 79-07 04/1'4/79' 05/29779 08/06/79 G03-79-1455 80 02 Faulty Overcurrent Trip Device in 08/05//9 79-11 evT Avo9 fnr ESF Systems i C5/22/79 07/22/79 08/la/79 no nusber 80'-02 79-14
.saisticJnalysis."for As-6uilt Safety-i
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GO:A 922r101
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11/05/79 o l oad 4ystems
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'07/02/79"
'11/02/79" lY1/d777'9' n
79-15
. Deen _DrAf_t Eump_.0. ficiencies l $7711/79 l09/12/79 I10/09/79. _ _. _
G03-79-1871 e
1 10/03/i9 TT 7500/1 I
I Pntential_ Failure of Emergency Tran'sY1Y/79 ~- ^10/27/79 l ro/03/ #9numoe'r~
~80-02 11 niesel Generator Field Exciter i
11/13/79 79-23
.Eailur.es_of W.estingnouse BFD Relays j
j Ul/Zd/6U c fatv Related Systems 11'/02/79 I01/02/79 02/04/80 I no numb,er.
0!O2 8
70-25 in a
70-?R
_ Passible _nal.furiction _of..j{amco Model t.Muu 02/07/8u 1 init Switches at Elevated Temp.
12/07/79 02/07/80 02/1f/80-~
'G03-80 ~.238 80T02 Loss _of_Charc.ca.1 from Std Type. II.
2",
ELE-FJ-6U-L 11 90-03 Trw Ahsnrber Cells 02/05/80 03/23/80
03'/06/80' 03/03780 -
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vacimm Ccndi. tion _Resultin3 in EacQ C5/10/80 ELE-Gcs-du-uo 30-05 enchocicalVolureconjysHolduo ul/10780' (90 dav F C6'/f6/80-
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07/07/80.
G03-80-U S(
pn nR onn e ratinn Melds 04/07/80 (on dwi 06/18/80 07715/80~--
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O hn' M N Rydramotor-Actuator Deficiencies 04/17/80 2 8
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pn_no
_ Contamination.of Monradioactive System t!o response req'd Tor
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o tential. for Release 05~/06/80~
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. Potential Misapplication of.Rosemosnt
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u d 1151/1152 w/A or 0 outohtC6'/27/80 08/26/80 on 16 v" Toe n
Failures. of H0. Wetted Matrix. Relays in, RF5.
pn 1o ce nf re olants 07/31/80 10/29/80, 90-?0 l Failures of W Type W-2 Spring Retu n to
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9, t,1 ceten1 ewitches 07/31/80 09/15/80 78-12 Atypical Weld Mati in RV Welds G03-80-531 an n9/29/78 n m 1/nn 03/17/80 N.
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Page 1 of 2 WNP 3/5 ATTACHMENT 5 Experience during the appraisal period indicates that the 'icensee needs to direct attention toward:
1.
Assuring that adequate precaration and preplanning has been acco ulished prior to the start of safety-related work. Specifically that PSAR and code requirements, and. industry standards (as applicable) have been included in the contractor's program and are functionable.
2.
Assuring that vendor cuality programs are effective in providing msterial of the requisite quality level.
A.
Adem ate Preparation and Preplanning During the period of August 1979 to August 1980 several conditions were identified which indicated that the contractor's quality programs were not consistent with all requirements and were not fully effective prior to the start of safety related work activities, these include:
1.
Chicago Bridge and Iron (containment vessel contractor) quality assurance manual and implementing procedures were not wholly consistent with specification requirements (NRC Item 50-508/79-10) and code requirements (NRC Item 50-509/79-08-02).
i 2.
Peter Kiewit Sons' (prime mechanical contractor outside containment) quality assurance manual and implementing procedures were not wholly consistent with code arJ administrative site procedures (NRC Item 50-508/79-08-01).
3.
Morrison & Xnudsen (prime civil / structural contractor outside containment) had not established a system assure all structural steel joints receive appropriate inspection (lack of status control, MRC Item 50-508/509/30-06-02).
4.
Lack of effectiveness is demonstrated in workmanship / inspection deficiencies in weld quality (PC Items 50-508/79-07-02,50-509/
79-08-01, 50-508/80-06-03 and related finding in NRC Inspection Report 50-508/80-08).
Contributory to the noted conditions of lack of consistency and effective implementation is the large number of site contractors and the correspondingly large number of QA programs and icolementing procedures, diluting the effectiveness of the licensee / construction manage QA organization.
These conditions are also exemplified by inconsistencies and different contractors' procedures for a particular task.
For example:
i
BNP 3/5 Page 2 of 2 ATTACHMENT 5 i Comparison of six major contractor's (ftorrison & Knudsen, Chicago Bridge & Iron, Peter Kiewit Sons', Mallace/Suoerior, Fischbach and
'400re, and J. A. Jones) quality procedures for inspecting and documenting a fillet' weld reflects a variety of guidance for executing the same j
activity.
Specifically, some crocedures provide essentially all inspection requirements and acceptance criteria, some make reference to the code for reouirements and/or criteria, some indicate the code may be used. Regarding inspection technique some discuss the use of tools (gages / lights / magnifiers), others do not; one provides specific details regarding minimum light levels and proximity of the eye to the weld. Regarding documentation, some require documentation on a sinole report / data sheet, two require documentation on two forms, and some reautre physically marking the weld joint.
It appears that the licensee's efforts to imorove preparation and preplanning should include additional efforts to unify quality policy / policy interpretation through consistency in procedures and related activities (e.g. training, documentation).
It is noted that in response to the 1978 Enforcement Conference the licensee indicated efforts would be made to standardize construction procedures.
j B.
Vendor Quality proarams Du*ing the appraisal period the NRC issued two items of noncompliance regarding unsatisfactory weld quality or vendor supplied material (50-50?/
80-04-02 and -03).
In addition licensee site representatives have identified inadequacies in vendor supplied safe shut down heat exchangers (reported to the NRC as a 50.55(e) item), auxiliary feedwater pumps, pipe supports, and safety-related valves. Subsequent to the appraisal period (in September 1980) the NRC identified inadequate welding on vendor supplied gas decay tanks (NRC Report 50-508/80-09).
In each of the above cases the materials involved had been included in a vendor quality program and a vendor surveillance program.
Due to concerns about the effectiveness of these programs the latest imC Inspection Report to the licensee (!!o. 50-508/
509/80-09) requests further actions by the licensee in this area.